William K. Henson

A manufacturable dual channel (Si and SiGe) high-k metal gate CMOS technology with multiple oxides for high performance and low power applications

Band-gap engineering using SiGe channels to reduce the threshold voltage (VTH) in p-channel MOSFETs has enabled a simplified gate-first high-к/metal gate (HKMG) CMOS integration flow. Integrating Silicon-Germanium channels (cSiGe) on silicon wafers for SOC applications has unique challenges like the oxidation rate differential with silicon, defectivity and interface state density in the unoptimized state, and concerns with Tinv scalability. In overcoming these challenges, we show that we can leverage the superior mobility, low threshold voltage and NBTI of cSiGe channels in high-performance (HP) and low power (LP) HKMG CMOS logic MOSFETs with multiple oxides utilizing dual channels for nFET and pFET.

Design and Fabrication of MOSFETs with a Reverse Embedded SiGe (Rev. e-SiGe) Structure

A novel device structure containing a SiGe stressor is used to impose tensile strain in nMOSFET channel. 400MPa of uniaxial tensile stress is induced in the Si channel through elastic relaxation/strain of the SiGe/Si bi-layer structure. This strain results in 40% mobility enhancement and 15% drive current improvement for sub-60nm devices compared to the control device with no strain

Strained Si Channel MOSFETs with Embedded Silicon Carbon Formed by Solid Phase Epitaxy

Current drive enhancement is demonstrated in sub-40 nm NFETs with strained silicon carbon (Si:C) source and drain using a novel solid-phase epitaxy (SPE) technique for the first time. The very simple process uses no recess etch or epi deposition steps, adds minimal process cost, and can be easily integrated into a standard CMOS process. With a record high 1.65 at% substitutional C concentration in source and drain, 615 MPa uniaxial tensile stress was introduced in the channel, leading to a 35% improvement in electron mobility and 6% and 15% current drive increase in sub-40 and 200 nm channel length devices respectively.

Investigation of emerging middle-of-line poly gate-to-diffusion contact reliability issues

The minimum insulator spacing between the polysilicon control gate (PC) and the diffusion contacts (CA) in advanced VLSI circuits is aggressively shrinking due to continuous technology scaling. Meanwhile, rapid adoptions of new materials such as metal gate, epitaxial SiGe source /drain, stress liner, and copper contact together with new device configurations such as raised source/drain and FinFET may further exacerbate the PC-CA dielectric reliability. SRAM yield loss and functional stress failures of both SRAM and DRAM chips due to middle-of-line (MOL) PC-CA shorts and early breakdown have been observed during the course of technology development at 32nm. Therefore, the leakage and breakdown of middle-of-line (MOL) PC-to-CA dielectric is rapidly becoming an emerging reliability issue for a successful technology development. In this paper, a comprehensive investigation of MOL PC-to-CA reliability issues at 32nm technology node was conducted. A new qualification methodology was developed to assure PC-to-CA reliability at an acceptable level.

Effect of plasma N2 and thermal NH3 nitridation in HfO2 for ultrathin equivalent oxide thickness

Two methods of HfO2 nitridation including plasma N2 nitridation and thermal NH3 anneal were studied for ultrathin HfO2 gate dielectrics with <1 nm equivalent oxide thickness (EOT). The detailed nitridation mechanism, nitrogen depth profile, and nitrogen behavior during the anneal process were thoroughly investigated by XPS and SIMS analysis for the two types of nitridation processes at different process conditions. Intermediate metastable nitrogen was observed and found to be important during the plasma nitridation process. For thermal NH3 nitridation, pressure was found to be most critical to control the nitrogen profile while process time and temperature produced second order effects. The physical analyses on the impacts of various process conditions are well correlated to the electrical properties of the films, such as leakage current, EOT, mobility, and transistor bias temperature instability.

A 0.039um 2 high performance eDRAM cell based on 32nm High-K/Metal SOI technology

We present industrys smallest eDRAM cell and the densest embedded memory integrated into the highest performance 32nm High-K Metal Gate (HKMG) SOI based logic technology. The cell is aggressively scaled at 58% (vs. 45nm) and features the key innovation of High-K Metal (HK/M) stack in the Deep Trench (DT) capacitor. This has enabled 25% higher capacitance and 70% lower resistance compared to conventional SiON/Poly stack at matched leakage and reliability. The HKMG access transistor developed in high performance optimized technology features sub 3fA leakage and well-controlled threshold voltage sigma of 40mV. The fully integrated 32Mb product prototypes demonstrate state of the art performance with excellent retention and yield characteristics. The sub 1.5ns latency and 2ns cycle time have been verified with preliminary testing whereas even better performance is expected with further characterization. In addition, the trench capacitors set the industry benchmark for the most efficient decoupling in any 32nm technology.

Advanced modeling and optimization of high performance 32nm HKMG SOI CMOS for RF/analog SoC applications

We demonstrate advanced modeling and optimization of 32nm high-K metal gate (HKMG) SOI CMOS technology for high-speed digital and RF/analog system-on-chip applications. To enable high-performance RF/analog circuit design, we present challenging device modeling features and their enhancements. At nominal Lpoly, floating-body NFET and PFET demonstrate peak fT of 300GHz and fMAX of higher than 350GHz with excellent model-to-hardware accuracy. For precision analog circuit design, body-contacted (BC) FETs and various passives are offered, and their performance and modeling accuracy are co-optimized to push the technology limit and achieve state-of-the-art circuits, e.g., 28Gb/s serial link transceiver and LC-tank VCO operating at higher than 100GHz.

Stress Liner Effects for 32-nm SOI MOSFETs With HKMG

Strain effects from stress liners on silicon-on-insulator MOSFETs with high-k dielectric and metal gate (HKMG) are reported. By thoroughly evaluating their impact on drive current, mobility, and threshold voltage, the intrinsic performance gain of stress liners is quantified at the 32-nm node with mobility enhancement identified as the major source. It is also experimentally demonstrated that advantageous stress liners can reduce gate leakage currents for MOSFETs with HKMG.

New electrical testing structures and analysis method for MOL and BEOL process diagnostics and TDDB reliability assessment

Both MOL PC-CA spacer dielectric and BEOL low-k dielectric breakdown data are commonly convoluted with multiple variables present in the data due to the involvement of many process steps such as lithography, etch, CMP, cleaning, and thin film deposition. With the continuing aggressive scaling of device dimensions and introduction of new device configurations, how to accurately analyze such complicated lateral dielectric breakdown data from MOL and BEOL TDDB in advanced VLSI circuits has become very challenging. In this paper, a new electrical method is developed to accurately characterize different variables in MOL and BEOL dielectric breakdown. This method provides a powerful way to do a fast deep dive process and reliability analysis for technology development and qualification without time consuming physical failure analysis.

A novel ALD SiBCN low-k spacer for parasitic capacitance reduction in FinFETs

FinFET has become the mainstream logic device architecture in recent technology nodes due to its superior electrostatic and leakage control [1,2,3,4]. However, parasitic capacitance has been a key performance detractor in 3D FinFETs. In this work, a novel low temperature ALD-based SiBCN material has been identified, with an optimized spacer RIE process developed to preserve the low-k value and provide compatibility with the down-stream processes. The material has been integrated into a manufacturable 14nm replacement-metal-gate (RMG) FinFET baseline with a demonstrated ~8% performance improvement in the RO delay with reliability meeting the technology requirement [4]. A guideline for spacer design consideration for 10nm node and beyond is also provided based on the comprehensive material properties and reliability evaluations.